EP1855781B1 - Bande collectrice de fibres pour un devesiculeur - Google Patents

Bande collectrice de fibres pour un devesiculeur Download PDF

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Publication number
EP1855781B1
EP1855781B1 EP06717655A EP06717655A EP1855781B1 EP 1855781 B1 EP1855781 B1 EP 1855781B1 EP 06717655 A EP06717655 A EP 06717655A EP 06717655 A EP06717655 A EP 06717655A EP 1855781 B1 EP1855781 B1 EP 1855781B1
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EP
European Patent Office
Prior art keywords
fiber bed
collecting media
media strip
layer
set forth
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP06717655A
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German (de)
English (en)
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EP1855781A2 (fr
Inventor
Steven A. Ziebold
Douglas E. Azwell
Frederick L. Mueller
John S. Merz
Pierre L. Eemans
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MECS Inc
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MECS Inc
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Priority to EP12157187A priority Critical patent/EP2510997A1/fr
Priority to PL06717655T priority patent/PL1855781T3/pl
Publication of EP1855781A2 publication Critical patent/EP1855781A2/fr
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Publication of EP1855781B1 publication Critical patent/EP1855781B1/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/56—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition
    • B01D46/62—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition connected in series
    • B01D46/64—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition connected in series arranged concentrically or coaxially
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2003—Glass or glassy material
    • B01D39/2017—Glass or glassy material the material being filamentary or fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0027—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions
    • B01D46/003—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions including coalescing means for the separation of liquid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0027—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions
    • B01D46/003—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions including coalescing means for the separation of liquid
    • B01D46/0031—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions including coalescing means for the separation of liquid with collecting, draining means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
    • B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
    • B01D46/522—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material with specific folds, e.g. having different lengths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/56—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition
    • B01D46/58—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition connected in parallel
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D11/00—Double or multi-ply fabrics not otherwise provided for
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D3/00—Woven fabrics characterised by their shape
    • D03D3/02—Tubular fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0414—Surface modifiers, e.g. comprising ion exchange groups
    • B01D2239/0428—Rendering the filter material hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0622—Melt-blown
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0654—Support layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0677—More than one layer present in the filtering material by spot-welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0686—More than one layer present in the filtering material by spot-gluing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/069—Special geometry of layers
    • B01D2239/0695—Wound layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1233—Fibre diameter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2275/00—Filter media structures for filters specially adapted for separating dispersed particles from gases or vapours
    • B01D2275/10—Multiple layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2275/00—Filter media structures for filters specially adapted for separating dispersed particles from gases or vapours
    • B01D2275/10—Multiple layers
    • B01D2275/105—Wound layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2275/00—Filter media structures for filters specially adapted for separating dispersed particles from gases or vapours
    • B01D2275/20—Shape of filtering material
    • B01D2275/206—Special forms, e.g. adapted to a certain housing

Definitions

  • This invention relates generally to fiber bed mist eliminators, and fiber beds and collecting media therefor.
  • Fiber bed mist eliminators have wide industrial application in the removal of aerosols from gas streams.
  • the generation of aerosols ("mist") in gas streams is common in the course of manufacturing processes. Aerosols can be formed, for instance, as a result of mechanical forces (e.g., when a flow including a liquid runs into a structure) that atomize a liquid. Cooling of a gas stream may result in the condensation of vapor to form a mist, and chemical reactions of two or more gases may take place at temperatures and pressures where the reaction products are mists.
  • the aerosol comes to be in the gas stream, it can be undesirable to inject the aerosol into other processing equipment because the aerosol may be corrosive or otherwise lead to damage or fouling of the processing equipment.
  • fiber bed mist eliminators include removal of acid mists, such as sulfuric acid mists, in acid manufacturing, removal of plasticizer mists in the manufacture of polyvinyl chloride floor or wall coverings and removal of water-soluble solid aerosols from the emissions of ammonium nitrate prill towers.
  • fiber bed mist eliminators may achieve separation efficiencies of 99% or greater depending upon, among other things, the thickness of the fiber bed.
  • fibers made of various materials may be used to construct fiber beds for fiber bed mist eliminators.
  • the fiber bed is designed to collect fine liquid mist and soluble solid particles entrained in a moving gas stream and drain them through the structure of the bed.
  • beds of collecting fibers are associated with metal wire screens or similar external support structures.
  • the combination of a bed of collecting fibers and external support structure is known as a fiber bed assembly.
  • fiber bed refers to that portion of the fiber bed assembly apart from any such support structure.
  • Fiber beds may be formed by packing bulk fiber between two opposing support screens (bulk-packed beds), pre-forming a tube of fiber bed material, or winding a roving made of fibers around a cylindrical support screen (wound beds).
  • fiber bed assemblies are most often configured in the form of a vertical cylinder. Cylindrical fiber bed assemblies permit a high effective fiber bed surface area in a minimum of space. Flat fiber bed assemblies on the other hand, find particular application for smaller gas flows.
  • U.S. Patent No. 3,093,469 describes oil mist separators that include a glomerating medium 49, which may be formed of glass or other suitable fibers. The glomerating medium is applied in layers 50 to facilitate dense compaction. The glomerating medium 49 is compacted and secured together using inner and outer cylindrical shells or walls 42 and 43.
  • a horizontal stream of gas containing a liquid and/or wetted soluble solid aerosol is made to penetrate and pass through the fiber bed of the fiber bed assembly.
  • the fibers in the fiber bed capture the aerosol in the gas by the mechanisms of impaction, interception, and Brownian diffusion.
  • the captured aerosol coalesces on the fibers to form droplets of liquid in the fiber bed.
  • the moving gas urges the droplets to move toward the downstream face of the fiber bed where the captured liquid exits the fiber bed and drains downward under the force of gravity.
  • the fibers which make up the fiber bed may be made from a variety of materials.
  • Materials utilized to make bed fiber include, for example, metals such as stainless steel, titanium, etc., fibers of polymeric materials such as polyesters, polyvinylchloride, polyethylene terphthalate, nylons, polyethylene, polypropylene etc., and glass.
  • metals such as stainless steel, titanium, etc.
  • fibers of polymeric materials such as polyesters, polyvinylchloride, polyethylene terphthalate, nylons, polyethylene, polypropylene etc., and glass.
  • the bulk density of prior art fiber beds ranges from about 5 lb/ft 3 (80 kg/m 3 ) to greater than 20 lb/ft 3 (320 kg/m 3 ), while fiber bed thickness ranges from about 0.5 to about 6 inches (1 to 15 cm) or more, depending upon the desired separation efficiency.
  • a mechanically stable fiber bed is one which will retain its structural integrity without substantial shifting of the fibers relative to adjacent fibers when exposed to the forces exerted by the gas being treated and the captured and draining liquid during aerosol collection. If mechanical stability is not maintained, the performance characteristics of the bed will be unfavorably altered.
  • the moving gas stream forces the fibers to shift substantially, causing the liquid ladened fibers in some portions of the fiber bed to mat or felt while increasing the void space between adjacent fibers in other portions of the fiber bed. Matted portions of the fiber bed are more resistant to both the flow of gas and the drainage of captured liquid.
  • Captured liquid which is unable to drain is often reentrained by the moving gas stream, resulting in reduced separation efficiency. Also, the pressure drop across matted portions of an unstable fiber bed is increased. On the other hand, in those portions of a mechanically unstable fiber bed where fiber shifting has increased the average void space between adjacent fibers, macroscopic pores or channels form which reduce separation efficiency by allowing the aerosol containing gas to pass through the fiber bed without sufficient contact with the collecting fibers.
  • mechanical stability is largely dependent upon the bulk density of the fiber bed.
  • a fiber bed bulk density within the range disclosed by the prior art typically provides sufficient contact between adjacent fibers to prevent substantial movement of the fibers when exposed to the forces exerted by the moving gas stream.
  • An effective fiber bed is a relatively open structure that allows free gas flow and liquid drainage even when the collecting fibers are coated with collected liquid. There must be sufficient void space between adjacent fibers in the bed so that collected liquid is not able to bridge the space between adjacent fibers to such an extent that the adherence of collected liquid to the surface of fibers prevents the liquid from draining.
  • the thickness of a fiber bed can be decreased without a loss in separation efficiency by decreasing the average fiber diameter of the fiber material comprising the fiber bed.
  • the resulting void fraction is so low that the bed tends to flood under typical operating conditions.
  • conventional thin wound beds are inherently less uniform.
  • a flooded bed is a fiber bed in which captured liquid largely fills the void spaces between adjacent fibers in the fiber bed.
  • a flooded fiber bed is much like the matted portions of an unstable fiber bed.
  • the captured liquid in a flooded fiber bed cannot properly drain and instead may be reentrained in the moving gas stream at the downstream face of the fiber bed. Furthermore, the pressure drop across a fiber bed assembly is increased when the fiber bed is flooded. If a pressure differential across the fiber bed sufficient to overcome the force of adhesion and dislodge the collected droplets from the fibers is employed, the collected liquid is blown from the downstream face of the fiber bed where it is reentrained by the gas stream resulting in low separation efficiency and increased operating cost.
  • the specific fiber surface area expressed as the area of fiber per unit volume of the fiber bed, may be decreased by decreasing the bulk density of the bed (i.e., increasing the void fraction).
  • the bulk density of a bulk-packed or wound fiber bed comprising fibers having an average diameter less than about 5 microns is reduced to a value sufficient to avoid flooding, such fiber beds lack the mechanical stability necessary to withstand the forces exerted by the moving gas stream. As a result, the moving gas stream causes the fibers to shift substantially resulting in the fiber bed matting and/or channeling as previously described.
  • conventionally constructed high efficiency fiber bed assemblies comprise fiber beds 2 to 6 inches (6 to 15 cm) thick constructed of fibers having an average fiber diameter between 5 and 15 microns and having a bulk density between 5 and 15 lb/ft 3 (80 and 240 kg/m 3 ).
  • some other types of gas filters such as baghouse, clean room and breathing filters, may successfully utilize glass fibers with average diameters below 5 microns and may even include fibers having a diameter less than 1 micron.
  • these types of gas filters are distinguished from fiber bed mist eliminators in that they are typically designed to utilize pore and surface filtration in collecting solid particulates or only relatively small amounts of liquid aerosols. If used to collect liquid aerosols, they easily flood at the liquid loading rates typically encountered in fiber bed mist eliminators.
  • fiber bed mist eliminators are designed to allow comparatively large quantities of liquid entrained in a moving gas stream to penetrate the fiber bed where the liquid is captured and continuously drained. Therefore, a solution to the problems associated with utilizing small diameter fibers in fiber beds of fiber bed mist eliminators is neither shown nor suggested by the prior art concerned with such other gas filters.
  • Reentrainment of collected liquid by the moving gas stream at the downstream face of a fiber bed is often a problem in fiber bed mist eliminator applications, especially in operations characterized by high liquid loading rates or high gas stream velocities. Satisfactory solutions to this problem have included combining a layer of primary filtration fibers and a layer of drainage fibers to form a fiber bed.
  • the drainage layer is downstream of the primary filtration layer and usually comprises fibers with a larger average diameter than those fibers comprising the primary filtration layer.
  • Fiber bed assemblies of the prior art have several disadvantages resulting from shortcomings in the fiber bed.
  • Wound fiber bed assemblies are typically formed using a fiber roving which is roughly cylindrical in shape.
  • the roving is wound around a cylindrical forming screen and back and forth along the length of the screen. This requires skill and the appropriate machinery. Even if the winding is executed correctly, the resultant wound fiber bed may have significant differences in gas flow over the surface area of the bed. These variations are a result of the inherent difficulty of forming a uniform surface on a cylinder using a cylindrical roving. Normal variations in the roving material cause the roving to flatten to different degrees, which affects the uniformity of the fiber bed formed by the roving. The non-uniformity is particularly observed in wound fiber beds having smaller thicknesses.
  • a third disadvantage is that because fibers having an average fiber diameter of less than about 5 microns cannot be used effectively in constructing a conventional fiber bed without additional processing (e.g., needle punching), fiber bed thickness in applications requiring high separation efficiency cannot be reduced. If thinner high efficiency fiber beds were possible in severe industrial process environments, fiber beds could be configured into shapes that maximize the fiber bed surface area in a given volume available for a fiber bed mist eliminator. This would be analogous to the dry filter art where thin filter papers and felts allow high surface area filter forms via pleating. Thinner, high efficiency fiber beds having increased fiber bed surface area would allow the operating cost of fiber bed mist eliminators to be decreased by decreasing the pressure drop across the fiber bed.
  • a fiber bed assembly for a fiber bed mist eliminator used to remove aerosols and/or wetted soluble solids from a moving gas stream comprising:
  • a composite fiber bed collecting media strip for forming a fiber bed of a mist eliminator used to remove aerosols and/or wetted soluble solids from a moving gas stream, the fiber bed being adapted to cover a support structure of the mist eliminator for blocking flow of the gas stream through the support structure except for through the fiber bed, the fiber bed collecting media strip comprising:
  • FIG. 1 is a perspective of a mist eliminator with a portion of a tank thereof broken away to show a fiber bed assembly of the mist eliminator constructed according to the principles of the present invention
  • FIG. 2 is an enlarged perspective of the fiber bed assembly
  • FIG. 3 is an enlarged, fragmentary vertical section of the fiber bed assembly of Fig. 2 ;
  • FIG. 4 is an enlarged perspective of the fiber bed assembly with an outer screen removed to show a fiber bed of the fiber bed assembly
  • FIG. 5A is a cross section of a fiber bed collecting media strip used to form the fiber bed
  • FIG. 5B is a cross section of a modified fiber bed collecting media strip
  • FIG. 5C is a perspective of a pleated fiber bed collecting media strip
  • FIG. 6A is a fragmentary elevation of a flat side of the fiber bed collecting media strip
  • FIG. 6B is a fragmentary elevation of a tapered end of the fiber bed collecting media strip
  • FIG. 7 is an enlarged, fragmentary vertical section of a fiber bed assembly similar to Fig. 3 but showing a first modified fiber bed for use with a reverse flow mist eliminator;
  • FIG. 8 is an enlarged, fragmentary vertical section of a fiber bed assembly similar to Fig. 3 but showing a second modified fiber bed;
  • FIG. 9 is an enlarged, fragmentary vertical section of a fiber bed assembly similar to Fig. 3 but showing a third modified fiber bed;
  • FIG. 10 is an enlarged, fragmentary vertical section of a fiber bed assembly similar to Fig. 3 but showing a fourth modified fiber bed;
  • FIG. 11 is an enlarged, fragmentary vertical section of a fiber bed assembly similar to Fig. 3 but showing a fifth modified fiber bed;
  • FIG. 12 is a perspective of a roll of the fiber bed collecting media strip
  • FIG. 13 is a fragmentary perspective of a roll of a sheet of multiple fiber bed media joined together
  • FIG. 14A is a table showing performance results of a conventional fiber bed
  • FIG. 14B is a table showing performance of a fiber bed of the present invention.
  • FIG 15 is a table showing performance of fiber beds of the present invention.
  • a mist eliminator (indicated generally at 1) is of the type that can be placed in the flow line of a stream of gas to remove aerosols and/or wetted soluble solids from the stream of gas.
  • the mist eliminator is of the type that has particular application for use in gas streams having a liquid aerosol content (especially where there are liquid aerosol particles having a submicron size) to be removed from the gas stream.
  • the mist eliminator 1 includes a tank (generally indicated at 3) having a removable lid 5 sealingly attached to the tank to close an open top of the tank.
  • An annular mounting plate 7 within the tank 3 divides the tank into an upper chamber 9 and a lower chamber 11.
  • the gas stream may pass from the lower chamber 11 to the upper chamber 9 only through a center hole 13 of the annular mounting plate 7.
  • the tank 3 includes a gas stream inlet 15 for receiving a stream of gas ladened with aerosol and/or wetted soluble solids into the lower chamber 11 of the tank, and a filtered, clean gas stream outlet 17 in fluid communication with the upper chamber 9 in the tank to permit filtered, clean gas to pass out of the mist eliminator 1 to an exhaust or other processing equipment (not shown).
  • a fiber bed assembly is located in the lower chamber 11 of the tank 3 and has a generally tubular shape with a closed bottom and an open top.
  • the filter bed assembly 19 is sealingly mounted on the mounting plate 7 so that an open top of the filter bed assembly is in registration with the center hole 13 of the mounting plate. Gas cannot flow from the lower chamber 11 to the upper chamber 9 unless it passes through the fiber bed assembly 19.
  • the mounting plate 7 supports the filter bed assembly 19 within the tank 3 so that the filter bed assembly hangs down from the mounting plate.
  • the fiber bed assembly removes a very high percentage of the aerosol and/or wetted soluble solids from the gas stream, which is drained to the bottom of the tank 3.
  • a drain pipe 21 near the bottom of the tank 3 drains off liquids and/or wetted soluble and dissolved solids that are collected in the bottom of the tank.
  • the illustrated mist eliminator 1 of Fig. 1 is a forward flow or "hanging style" mist eliminator. It is also known to have a reverse flow mist eliminator (not shown).
  • the construction of a fiber bed of the reverse flow mist eliminator will be described further in relation to Fig. 7 , but generally speaking the flow of the gas stream is opposite the flow in a forward flow mist eliminator as shown in Fig. 1 .
  • the gas stream would enter through what has been designated the gas stream outlet 17 of the mist eliminator 1 of Fig.l.
  • the gas would pass into the fiber bed assembly 19 through the center hole 13 of the mounting plate 7 and open top of the fiber bed assembly.
  • the gas would then pass radially outwardly through the fiber bed assembly 19 and out through the gas stream inlet 15.
  • Liquid and wetted or dissolved soluble solids captured by the fiber bed assembly 19 would be drained from the outside of the assembly into the bottom of the tank 3 in a reverse flow mist eliminator and removed by something like the tank drain pipe 21. It will be understood that the present invention applies to both forward and reverse flow mist eliminators.
  • fiber bed assembly 19 of the forward flow mist eliminator 1 includes a drain leg 25 that is spaced above the bottom of the tank 3.
  • the drain leg 25 comprises a drain tube 25A, a circular bottom plate 25B, and a passage 25C extending through the drain tube and opening at the bottom plate.
  • the passage 25C opens into the tank 3 for draining collected liquids and particles removed from the gas stream by the fiber bed assembly 19.
  • the liquid and wetted or dissolved soluble solids collected in the bottom of the tank 3 are drained through drain pipe 21.
  • An inner screen and an outer screen extend up from the bottom plate 25B to the mounting plate 7 and are concentrically arranged in radially spaced relation.
  • the inner and outer screens 27, 29 constitute a wall in the illustrated embodiment that separates an interior (downstream) space 31 within the inner screen 27 from an exterior (upstream) space 33 within the tank 3 but outside the inner screen 27. It will be understood that the wall may be constructed in other ways (e.g, having only a single screen or no screen) without departing from the scope of the present invention.
  • the inner and outer screens 27, 29 are of a generally mesh construction so that they each define relatively large openings that would permit the gas stream to move generally freely though the inner and outer screens between the interior space 31 and the exterior space 33.
  • the screens 27, 29 are connected to an annular flange 34 which is disposed on the top side of the annular mounting plate 7.
  • the annular flange 34 is attached to the mounting plate 7 and supports the screens 27, 29 and drain leg 25.
  • the inner screen 27, outer screen 29 and annular flange 34 comprise a fiber bed support. It is to be understood that other constructions for supporting a fiber bed may be used without departing from the scope of the present invention.
  • a fiber bed (generally indicated at 35) of the fiber bed assembly 19 is located in the radial space between the inner and outer screens 27, 29 and substantially fills the space and covers the openings in the screens so that the gas stream must pass through the fiber bed to move from the exterior space 33 surrounding the fiber bed assembly to the interior space 31 within the fiber bed assembly (see Fig. 1 ).
  • the fiber bed 35 is generally tubular in shape and operatively sealed at opposite ends to the mounting plate 7 and to the bottom plate 25B of the drain leg 25 in a way known to those of ordinary skill in the art so that gas does not bypass the fiber bed in flowing from the exterior space 33 in the tank 3 to the interior space 31.
  • An elongate, generally flat fiber bed collecting media strip, generally indicated at 37, is used to form part of the fiber bed 35.
  • the fiber bed collecting media strip 37 (or “pocket strip filter”) is wound in a spiral around the inner screen 27.
  • the ends of the fiber bed collecting media strip 37 taper in width substantially to a point.
  • An edge 38 of the taper (see Fig. 6B ) is positioned to extend circumferentially at one end of the inner screen 27 and thereby sets the angle of the spiral.
  • the wrapping is carried out so that adjacent turns 39 of the fiber bed collecting media strip 37 overlap each other. Additional pieces 36 of the fiber bed collecting media strip 37 may be applied at the ends of the fiber bed 35 or elsewhere as needed to form a continuous fiber bed surface completely covering the inner screen 27.
  • the additional pieces 36 of the fiber bed collecting media strip can be wrapped in a circle (rather than a spiral) next to the ends of the inner and outer screens 27, 29 to fully cover the ends.
  • Glass roving (not shown) may also be used at the ends of the fiber bed 35 to assure sufficient gas sealing.
  • a fiber bed may be formed other than by a spiral wrap within the scope of the present invention.
  • a fiber bed could be formed by a cylindrical tube of the fiber bed collecting media strip having a width equal to the height of the inner and outer screens 27, 29.
  • a drainage layer 41 located between the wrapped fiber bed collecting media strip 37 and the inner screen 27 receives liquid and wetted or dissolved soluble solids from fiber bed collecting media strip and transports them to the bottom of the fiber bed 35 for draining out through passage 25C in drain tube 25A into the tank 3 ( Fig. 1 ).
  • the drainage layer 41 covers the entire exterior surface of the inner screen 27. Any suitable material that drains freely while also permitting gas to pass through it may be used for the drainage layer 41.
  • drainage layer 41 may be like the drainage layers disclosed is co-assigned U.S. Patent Nos. 4,086,070 and 4,249,918 .
  • the outer screen 29 is applied over the wrapped fiber bed collecting media strip 37 on the inner screen 27, and compresses the wrap to seal the joints between adjacent, overlapping turns 39 of the fiber bed collecting media strip, as shown in Fig. 3 .
  • Each of the inner and outer screens 27, 29 are formed by an array of vertical wires (45 and 49, respectively) and horizontal wires (47 and 51, respectively) that are joined together where they overlap each other.
  • the horizontal wires 47 of the inner screen 27 are located on the exteriors of the vertical wires 45 of the inner screen.
  • the horizontal wires 51 of the outer screen 29 are located on the interiors of the vertical wires 49 of the outer screen.
  • the locations of the horizontal wires of the inner screen 27 and outer screen 29 are configured so that, as the inner and outer screens are arranged in the fiber bed assembly 19, the horizontal wires 47 of the inner screen are vertically offset from the horizontal wires 51 of the outer screen.
  • the horizontal wires 47, 51 therefore do not form pinch points that could decrease the functionality of the fiber bed 35.
  • the alternating arrangement of the horizontal wires 47, 51 forces the fiber bed 35 into a somewhat undulating configuration that acts to grip the fiber bed and hold it in securely in position and particularly against movement axially of the fiber bed.
  • Figure 3 is drawn to illustrate the fiber bed 35 in its actual condition between the inner and outer screens 27, 29.
  • the outer screen 29 compresses the fiber bed 35 against the inner screen 27 to stabilize the fiber bed and seal between adjacent turns 39 of the fiber bed collecting media strip 37.
  • Other similar views ( Figs. 7-11 ) illustrate the fiber bed schematically (as it might appear prior to compression by the outer screen 29).
  • the fiber bed collecting media strip 37 preferably has a composite structure including an inner layer 57, and outer layer 59 and an intermediate layer 61 sandwiched between the inner and outer layers ( Fig. 5A ).
  • the inner and outer layers 57, 59 are formed of a fibrous material which exhibits good strength characteristics, but may be less efficient in removing aerosols and/or wetted soluble solids from the gas stream.
  • the intermediate layer 61 is also formed of a fibrous material that is highly efficient in removing aerosols and/or wetted soluble solids from the gas stream, but has lesser strength than the inner and outer layers 57, 59.
  • the inner and outer layers can be needle punched, while the intermediate layer 61 is not needle punched.
  • the intermediate layer 61 is free of any discontinuities (such as may be caused by needle punching) that could provide a flow path for the gas stream to bypass the fibers in the layer.
  • the inner and outer layers 57, 59 can be made of any suitable fibrous material, such as ECOMAT 300 needle punched nonwoven glass fiber mat available in this country from Johns Manville Corporation of Denver, Colorado. Other materials are possible, such as ECOMAT 180 scrim reinforced glass fiber mats available from Johns Manville. The ECOMAT 180 mats are thinner than the ECOMAT 300 mats for a more compact fiber bed 35.
  • the intermediate material can be, for example, JM B015 glass fiber mat, also available from Johns Manville Corporation.
  • the JM B015 mat is a nonwoven, meltblown glass fiber batting.
  • the intermediate layer may be formed by multiple glass fiber mats.
  • the fibers in the inner and outer layers 57, 59 of the fiber bed collecting media strip 37 may have, for example, average diameters of about 6 to 8 microns or more.
  • the fibers in the intermediate layer are preferably smaller, such as about 5 microns or less in average diameter. More preferably, the fibers in the intermediate layer 61 have an average diameter of about 4 microns or less.
  • fibers in the intermediate layer 61 which have the same or greater average diameter than fibers forming the inner and outer layers 57, 59 may be used within the scope of the present invention.
  • the fibers used are long staple fibers (e.g., 0.25 inches to 6 inches or 0.6 cm to 15 cm) that are not chemically bonded.
  • the fibers are sufficiently entangled or fixed to form a stable bed when mounted on the mist eliminator.
  • the fibers should be durable under process conditions and preferably are not chemically bonded together. Glass fibers are desirable in certain highly corrosive environments, such as where the gas stream contains sulphuric acid. However, the fibers may be polymeric or other material suitable for particular applications.
  • the fibers of the intermediate layer 61 may be treated so that they are resistant to wetting by the aerosol in the gas stream.
  • the inner and outer layers 57, 59 may also be treated to be resistant to wetting by the aerosol.
  • the anti-wetting treatment of the inner and outer layers 57, 59 and the intermediate layer 61 further facilitates removal of the aerosol from the gas stream by keeping these layers from holding the aerosol (and wetted or dissolved soluble solids) once it is removed from the gas stream.
  • the drainage layer 41 is preferably formed or treated to be wettable.
  • the intermediate layer 61 is formed by longer fibers having a larger diameter, and shorter, smaller diameter fibers are interspersed within the larger fibers.
  • the smaller fibers may have an average diameter of about 3 microns or less. In one instance, the smaller fibers have an average diameter of between about 0.01 microns and 3 microns. The smaller fibers are believed to assist in holding the larger fibers apart to preserve void spaces within the intermediate layer 61, even under compression.
  • the inner and outer layers 57, 59 are connected together by stitching 65 along opposite longitudinal edge margins of the inner and outer layers.
  • the stitching 65 also extends through the intermediate layer 61 at the longitudinal edge margins.
  • the stitching 65 is formed with polytetrafluoroethylene coated thread for resistance to the corrosive aerosol in the gas stream, but other materials may be used.
  • other ways of joining inner layer 57, outer layer 59 and intermediate layer 61 together may be used within the scope of the present invention. For instance, the layers may be joined by stapling, heat fusing and gluing, or in another suitable manner (not shown).
  • a fiber bed collecting media may be formed by laying down fibers forming the equivalent of an intermediate layer in terms of its ability to remove aerosols and/or wetted soluble solids from a gas stream directly onto a layer of needle punched or otherwise reinforced material (e.g., like the outer or inner layer).
  • a layer of needle punched or otherwise reinforced material e.g., like the outer or inner layer.
  • glass meltblown fibers laid directly onto the glass fibers of a reinforced layer can fuse with the reinforced layer so as to become permanently attached and supported by the reinforced layer.
  • either the inner or outer layer would not necessarily be present in the fiber bed collecting media strip.
  • at least one of the inner and outer layers may be replaced by glass scrim.
  • FIGs 5B and 5C illustrate two possible variations in the construction of the fiber bed collecting media strip, which are designated generally at 37' and 37", respectively.
  • the fiber bed collecting media strip 37' incorporates a drainage layer 41' between the inner and outer layers 57', 59' of the media. More specifically, the drainage layer 41' is located between the intermediate layer 61' and the inner layer 57' for use in the forward flow mist eliminator.
  • the fiber bed collecting media strip 37' may be used with or without another drainage layer (not shown) covering the inner screen 27.
  • the second variant of the fiber bed collecting media strip 37" shown in Fig. 5C may have the same construction as the fiber bed collection media 37, 37' shown in Fig. 5A or Fig. 5B .
  • the collecting media strip 37" has been pleated to increase the surface area of the colleting media.
  • Formed wire screens 40" are used to hold the media 37" in the pleated configuration.
  • the thickness of the fiber bed collecting media strip 37 can be different for different applications and different acceptable efficiencies.
  • the fiber bed collecting media strip 37 has an uncompressed thickness of about 1 inch (3 cm). As compressed between the inner and outer screens 27, 29, the thickness is about 0.5 inches (1 cm).
  • the fiber bed collecting media strip has an uncompressed thickness of about 0.5 inches (1 cm). As compressed between the inner and outer screens 27, 29, the thickness is about 0.25 inches (0.6 cm).
  • the diameter of the inner screen 27 can be such that the fiber bed 35 has more total flow area compared to glass roving beds, even though the envelope in which the fiber bed assembly 19 is received is unchanged.
  • the larger flow area increases the capacity of the fiber bed assembly 19 without increasing its overall size.
  • the fiber bed collecting media strip 37 is applied to the inner screen 27 by wrapping the strip in a spiral from one end of the screen to the other.
  • Non-spiral end treatments e.g., additional pieces 36 and/or cylindrical rovings
  • the fiber bed collecting media strip 37 is wrapped so that each turn 39 of the spiral overlaps the previous turn. As may be seen in Fig. 3 , a portion of each lower turn 39 in the wrap overlies the turn immediately above it.
  • the width of the fiber bed collecting media strip 37 is about 18 inches (46 cm) but other widths (e.g., 24 inches or 61 cm) may be employed without departing from the scope of the present invention including a width equal to the height of the inner screen 27. In that case, the fiber bed collecting media strip would not be wound in a spiral, but formed as a tube to fit over the screen. Where a narrower fiber bed collecting media strip and a spiral wind are used as in the illustrated embodiment, each turn 39 overlaps the prior turn by about 2 to 6 inches (6 to 15 cm) and more preferably by about 2 to 3 inches (6 to 8 cm).
  • the overlap is selected so that there is a sufficient surface contact to inhibit gas from flowing between the turns 39 without passing through the fiber bed material (i.e., "gas bypassing").
  • the precise distance of overlap can be other than described herein without departing from the scope of the present invention. It is also envisioned that no overlap may be employed.
  • the fiber bed collecting media strip 37 is schematically illustrated as a unitary piece in Fig. 3 for simplicity of illustration. However, the fiber bed collecting media strip preferably has the composite configuration shown in Fig. 5 . Still further, multiple strips (non shown) may be used to form the spiral wrap.
  • the element is marked on its outer layer 59 with a dashed line 69 to show where to place the edge of the adjacent turn 39 when spirally wrapping the element on the inner screen 27.
  • the presence of the line 69 allows relatively unskilled labor to be used to form the fiber bed 35 using the fiber bed collecting media strip 37.
  • the fiber bed assembly 19 does not have to be sent to a remote installation for refurbishing and it may not be necessary to have a second fiber bed assembly ready for installation while the first is being refurbished. Wrapping of the fiber bed collecting media strip 37 can be carried out with little or no tension applied to the fiber bed collecting media strip.
  • the fiber bed collecting media strip 37 is wrapped so that each turn 39 of the element overlaps the turn immediately above it, and a bottom edge of the upper turn spaced away from the material of the lower turn and is exposed to the drainage layer 41 lying directly against the inner screen 27.
  • the exposed bottom edge of the upper turn 39 of the fiber bed collecting media strip 37 defines a drainage overhang 71 that allows liquids to flow out of the upper turn 39 and migrate directly to the drainage layer 41 without obstruction. It will be appreciated that gravity causes the liquids removed from the gas stream to move within the fiber bed collecting media strip 37 toward the bottom of each turn 39.
  • the liquid would flow down to the bottom of the fiber bed entirely within the material of the fiber bed collecting media strip.
  • liquid would tend to accumulate in the turns of the fiber bed collecting media strip at the bottom of the fiber bed because the fiber bed collecting media strip does not readily release the liquid.
  • Accumulated liquid provides a barrier to gas flow through the fiber bed so that not all portions of the fiber bed have about the same pressure drop (i.e., resistance to flow of gas through the fiber bed), reducing the effective useable area of the fiber bed and hence reducing the capacity of the fiber bed assembly.
  • the drainage overhang 71 of the present invention allows liquid to pass from one turn 39 of the fiber bed collecting media strip 37 directly to the drainage layer 41 instead of into the next turn of the fiber bed collecting media strip.
  • the liquid flows more readily so that none of the turns 39 of the fiber bed collecting media strip 37 tend to accumulate significantly more liquid than others, and the pressure drop across the fiber bed 35 is substantially uniform from top to bottom.
  • a first modified fiber bed 135 for a reverse flow mist eliminator is schematically illustrated in Fig. 7 in fragmentary cross section similar to Fig. 3 .
  • the reconfigured parts of the modified fiber bed 135 will be given the same reference number as the corresponding parts of the fiber bed 35, plus "100".
  • the gas stream flows from within the inner screen 27 radially outwardly through the fiber bed 135 past the outer screen 29.
  • the construction of the fiber bed 135 is similar to the fiber bed 35 of a standard flow mist eliminator 1 (as shown in Fig. 3 ) except as noted.
  • the drainage layer 141 is located against the inside of the outer screen 29 rather than against the inner screen 27.
  • the fiber bed collecting media strip 137 is wound in a spiral as before, but the wrapping is carried out so that each turn 139 overlaps the turn immediately below it, forming a drainage overhang 171 that is exposed directly to the drainage layer 141 on the outer screen 29.
  • the operation and advantages of the drainage overhang 171 are the same as for the drainage overhang 71 the standard flow mist eliminator 1.
  • a second modified version of the standard flow fiber bed schematically illustrated in Fig. 8 is generally similar in construction to the fiber bed assembly 19 shown in Fig. 3 .
  • the reconfigured parts of the modified fiber bed 235 will be given the same reference number as the corresponding parts of the fiber bed 35, plus "200".
  • a drainage strip 242 (broadly, "an intermediate drainage layer”) is spirally wound along with the fiber bed collecting media strip 237 so that the drainage strips are disposed between adjacent turns 239 of the fiber bed collecting media strip where they overlap.
  • the material of the drainage strip 242 can be the same as the master drainage layer 241.
  • the drainage strip 242 extends outward from the overlap and against the drainage layer 241 extending substantially the full height of the fiber bed 235. In so doing, the drainage strip 242 extends under the drainage overhang 271 formed by a bottom edge of the upper turn 239 of fiber bed collecting media strip 237 and is interposed everywhere between the drainage overhang and the next lower turn of the fiber bed collecting media strip. Liquid draining out of the upper turn 239 at the drainage overhang 271 that falls straight down hits the drainage strip 242 and is transported in the drainage strip to the drainage layer 241.
  • the drainage strip 242 enhances the ability of the fiber bed 235 to move liquid captured by the fiber bed collecting media strip 237 to the drainage layer 241 by providing a barrier (i.e., the drainage strip 242) between adjacent turns 239 of the fiber bed collecting media strip inhibiting transfer of liquid from one turn to the next.
  • the drainage strip 242 can be wrapped on the inner screen 27 together with the fiber bed collecting media strip 237 to produce the fiber bed illustrated in Fig. 8 .
  • the drainage strip 242 may be formed as a single continuous strip (as illustrated) or multiple shorter strips (non shown).
  • Figure 9 illustrates a third modified version of the fiber bed 335 in which three fiber bed media 337 are laid on top of each other with their longitudinal edges generally in registration, and then spirally wrapped onto the inner screen 27.
  • the number of fiber bed media arranged in a stack may be other than three within the scope of the present invention.
  • the reconfigured parts of the modified fiber bed 335 will be given the same reference number as the corresponding parts of the fiber bed 35, plus "300". Wrapping the overlaid fiber bed media 337 onto the inner screen 27 can otherwise be carried out in the same way as for the single layer fiber bed collecting media strip 37.
  • Fiber bed collecting media strip 337 may have the same construction as the fiber bed collecting media strip 37 shown in Fig. 5 , or other construction suitable for removing aerosols and/or wetted soluble solids from a gas stream.
  • a fourth modified version of the fiber bed 435 is shown in Fig. 10 to comprise two spirally wound wrappings layered one on top of the other on the inner screen 27.
  • the reconfigured parts of the modified fiber bed 435 will be given the same reference number as the corresponding parts of the fiber bed 35, plus "400".
  • Each wrapping is formed by its own fiber bed collecting media strip 437', 437", respectively.
  • the fiber bed collecting media strips 437', 437" are not laid over each other or wrapped in a single operation.
  • the first wrapping can be formed in the same way for the fiber bed of Fig. 3 .
  • the fiber bed collecting media strip 437' overlies the drainage layer 441 on the inner screen 27.
  • the second wrapping is formed by winding fiber bed collecting media strip 437" on the radially outer surface of the wrapped fiber bed collecting media strip 437'. It is to be understood that the number of wrappings may be more than two without departing from the scope of the present invention. Moreover another drainage layer (not shown) may be positioned between the wrappings.
  • One advantage of layered fiber bed constructions of Figs. 9 and 10 is that fiber beds for different applications can be formed with the same basic material (e.g., the fiber bed collecting media strip 37). Selecting the number of layers tailors the construction of the fiber bed for the particular job to be performed.
  • the fifth modified version of the fiber bed 535 shown in Fig. 11 Parts of the fiber bed 535 corresponding to the fiber bed 35 are given the same reference numeral, plus "500".
  • the fiber bed 535 is constructed with additional material at the seams where the adjacent turns 539 of the spirally wound fiber bed collecting media strip 537 overlap. It is believed that if gas bypassing were to occur, these overlap seams would be the most likely location. Accordingly, multiple strands 540 of a roving made of fiberglass or other suitable material are wound onto the radially exterior surface of the spirally wound fiber bed collecting media strip 537 over the seams to further seal the fiber bed 535 at the seams.
  • the roving 540 could be wrapped onto the inner screen 27 and the fiber bed collecting media strip 537 wrapped over it so that the overlap seams are in registration with the wrapped bands of roving.
  • Another possible option is to apply caulk (not shown) or other suitable sealant over the seams.
  • any such sealing structure should present as little obstruction to the flow of gas through the fiber bed 535 as possible.
  • the fiber bed collecting media strip 37 of the present invention can be used in the field and may be packaged in formats suitable for shipment to and use in the field.
  • fiber bed collecting media strip 37 formed such as shown in Fig. 3 can be wound onto a spindle 75 forming a roll (generally indicated at 77) for shipment.
  • the fiber bed collecting media strip 37 can be let out from the roll 77 to wind onto an inner screen 27 of a fiber bed assembly 19.
  • Another format shown in Fig. 13 has a single sheet of fiber bed material (generally indicated at 81) containing multiple (six) fiber bed collecting media strips 37A-37F arranged side-by-side and joined together.
  • the fiber bed material can be packaged on a roll indicated generally at 83.
  • the fiber bed material can be formed with an inner layer similar to inner layer 57 but extending the full width of the fiber bed material 81, an outer layer similar to outer layer 59 but extending the full width of the sheet 81 and an intermediate layer similar to intermediate layer 61 but extending the full width of the sheet.
  • An intermediate layer could also be separated into sections prior to assembly with the inner and outer layers.
  • Stitching 65A-65F formed by sewing or other suitable means can be formed along the edges of each individual fiber bed collecting media strips 37A-37F to unitize the components (i.e., an inner layer section, an outer layer section and an intermediate layer section) of each individual element. However, it is envisioned that the stitching 65A-65F could be omitted.
  • Lines 85 of perforations between adjacent fiber bed collection media 37A-37F form frangible portions that permit the connected strips 37A-37F to be torn apart for individual use.
  • Other ways of weakening the attachment between adjacent strips 37A-37F can be employed.
  • no lines of weakness could be preformed in the fiber bed material.
  • a cutting tool (not shown) could be used to separate the fiber bed collection media when needed.
  • a prototype fiber bed assembly 19 constructed according to the principles of the present invention was tested and its performance is compared to that of an existing fiber bed assembly.
  • the results of the tests for the existing fiber bed assembly are tabulated in Fig. 14A of the drawings and test results for the prototype fiber bed assembly 19 are tabulated in Fig. 14B .
  • the existing fiber bed assembly is a glass roving pack fiber bed assembly commercially available from Monsanto Enviro-Chem Systems, Inc. of St. Louis, Missouri.
  • the glass roving fiber bed assembly is formed by wrapping a fiber roving on a cylindrical screen.
  • the prototype fiber bed assembly 19 is formed by wrapping the fiber bed collecting media strip on the inner screen 27 to produce a fiber bed 135 substantially as shown in Fig. 7 (i.e., for reverse flow).
  • the fiber bed collecting media strip tested has the construction shown in Fig. 5 , except that the intermediate layer is formed by three JM B005 mats arranged in layers, and the inner and outer layers were joined together by stapling, rather than stitching.
  • the inner and outer layers are ECOMAT 300 fiber mats, as described for the illustrated embodiment above.
  • the overlap between adjacent turns 39 of the fiber bed collecting media strip in the wrap is about 2 inches (6 cm).
  • a drainage layer similar to Fig. 7 was formed using two fiber mats.
  • the fiber bed collecting media strip is 18 inches (46 cm) wide and 35 feet (10.7 m) long.
  • the outside diameter of the fiber bed 35 is 23.2 inches (58.9 cm), the inside diameter is 22 inches (56 cm), the compressed fiber bed thickness (including the drainage layer) is 0.6 inches (1.5 cm) and the height of the fiber bed is 6 feet (1.8 m).
  • the fiber bed area is 34.5 ft 2 (3.21 m 2 ) and the fiber bed volume is 1.8 ft 3 (0.05 m 3 ).
  • the total mass of fiber used in the collecting media strip 37 is 10.9 pounds (5.0 kg) and its volume is about 1.5 ft 3 (0.04 m 3 ).
  • the overall density of the collecting media strip is 7.4 lb/ft 3 (118.5 kg/m 3 ).
  • the overall numbers take into account the areas of overlap in the fiber bed.
  • the inner and outer layers of the fiber bed collecting media strip formed by the ECOMAT 300 mat are also 35 feet (10.6 m) long and 18 inches (46 cm) wide. The compressed thickness of both layers together is 0.25 inches (0.6 cm).
  • the overall fiber bed area of the layers is 42.5 ft 2 ( 3.95 m 2 ) and the combined volume of the layers is approximately 0.8 ft 3 .
  • the average fiber diameter of the inner and outer layers is 10.4 microns.
  • the total mass of fiber used is 5.0 lb (2.3 kg) and the overall density of the inner and outer layers is 6.8 lb/ft 3 (108.9 kg/m 3 ).
  • the intermediate layer formed by the JM B005 mat is also 35 feet (10.7 m) long and 18 inches (46 cm) wide.
  • the compressed thickness of the intermediate layer is 0.25 inches (0.8 cm).
  • the fiber bed area of the intermediate layer is 42.5 ft 2 ( 3.95 m 2 ) and the volume is approximately 0.8 ft 3 (0.02 m 3 ).
  • the total mass of fiber used is 5.9 lb (2.67 kg) and the density of the intermediate layer fiber bed is 7.9 lb/ft 3 (126.5 kg/m 3 ).
  • LVLL low velocity/low load
  • LVHL low velocity/high load
  • HVLL high velocity/low load
  • HVHL high velocity/high load
  • HVHL high velocity/high load
  • HHVLL extra-high velocity and low load
  • the first data column is a measure of the amount (or load) of aerosol (i.e., polyalpha-olefin oil mist) in the gas stream.
  • the second and third columns show velocity of the gas stream and the volume flow of gas per unit length (height) of the fiber bed 35.
  • the fourth through seventh columns contain data pertaining to the resistance to gas flow provided by the fiber bed 35.
  • the fourth column shows the pressure drop across the fiber bed 35.
  • the fifth and sixth columns show flow resistance (C o ), which is the ratio of the pressure drop over the gas stream velocity when the fiber bed 35 contains no liquid (column five) and when the fiber bed contains captured liquid from the gas stream (column six).
  • the seventh column (W/D) is the ratio of the wet flow resistance to the dry flow resistance.
  • Columns 8 through 12 show the efficiency of the fiber bed 35 in removing particles of the size (in microns) indicated.
  • the final column shows the overall efficiency of the fiber bed 35 at removing all combined particles sizes.
  • An Anderson Mark IV cascade impactor designed for gravimetrically measuring particle side distribution and aerosol loading in gas streams was used to acquire the data.
  • the fiber bed 135 constructed according to the principles of the present invention provides less resistance to flow of gas through the fiber bed while achieving the same or better efficiencies in removing particles.
  • the differences are particularly dramatic at low velocity and low load conditions.
  • LVLL low velocity/low load
  • the flow resistances in both wet and dry conditions for the prototype fiber bed 35 are lower than for the glass roving fiber bed.
  • HVLL high velocity/low load
  • Fig. 15 the performance of the fiber bed 35 of the present invention at different bed thicknesses under different conditions is shown.
  • Data for the efficiency of the fiber bed 35 at 0.6 inches (1.5 cm) compressed thickness is used to calculate results for fiber beds of other thicknesses.
  • the first condition is low velocity and low load (LVLL).
  • LVLL low velocity and low load
  • the gas stream velocity and aerosol load are the same, 23.4 ft/min (7.1 m/min) and 1.8 mg/ft 3 (64 mg/m 3 ), respectively.
  • the collection efficiency for particles in the gas stream having a size of 0.3 microns or more is nearly 100% until the thickness of the fiber bed is dropped to 0.3 inches (0.8 cm). There are many applications in which a lower efficiency is acceptable.
  • the efficiency falls off at a thickness of 0.3 inches (0.8 cm), the efficiency remains high enough for practical application.
  • the second set of conditions are for low velocity, but high load (LVHL).
  • the velocity is the same as for LVLL, but the mist to be removed is increased to 47.4 mg/ft 3 (1,674 mg/m 3 ).
  • the collection efficiency of 0.3 micron particles for fiber bed thicknesses from 0.6 inches (1.5 cm) to 1.2 inches (3.0 cm) remains very high. The efficiency drops off somewhat more for the fiber bed having a thickness of 0.3 inches (0.8 cm) than under LVLL conditions.
  • a third set of conditions is at a high velocity, but a low load.
  • the operation under low loading conditions is again very good for all thicknesses.
  • Substantially 100% of 0.3 micron particles are collected at all bed thicknesses.
  • the table in Fig. 15 shows data for collection of 0.2 micron particles so that some variation in efficiency can be demonstrated.
  • the fourth set of conditions is high velocity and high load. Again, at higher loads a greater differentiation in the collection of efficiency among the fiber beds of different thicknesses can be seen. However, the efficiencies remain within levels that have commercial application.
  • a fifth set of conditions includes an extra high velocity at a low load. Even under very high velocity conditions the fiber bed of the present invention is able to extract a large percentage of the aerosol particles from the gas stream.
  • the fiber bed and fiber bed collecting media strip of the present invention provide several advantages. It has high efficiency at low loading and low gas stream velocity, with very low pressure drop across the fiber bed. At thicknesses of perhaps double those tested (e.g., 1.2 inches or 3 cm compressed thickness), collection efficiencies in the HEPA range (99.997 percent at 5 inches of H 2 O or 1.25 kPa pressure drop) may be achieved. Moreover, the data support use of the collecting media strip at high gas stream velocities.

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Claims (30)

  1. Ensemble lit de fibres (19) pour un éliminateur de brouillard à lit de fibres (1) utilisé pour éliminer des aérosols et/ou des corps solides solubles mouillés à partir d'un courant gazeux mobile, l'ensemble lit de fibres comprenant:
    un support de lit de fibres (27, 29, 34) présentant une paroi (27, 29) définissant un espace amont (33) et un espace aval (31), la paroi (27, 29) comprenant des ouvertures dans celle-ci pour permettre au courant gazeux de se déplacer à travers la paroi (27, 29) de l'espace amont (33) à l'espace aval (31),
    un lit de fibres (35) supporté par le support de lit de fibres (27, 29, 34) et couvrant les ouvertures de paroi pour que le courant gazeux passe à travers le lit de fibres (35) se déplaçant de l'espace amont (33) à l'espace aval (31), le lit de fibres (35) comprenant une bande composite de matière de captage pour lit de fibres (37, 37', 37") comprenant :
    une couche extérieure (59, 59', 59") comprenant un tapis de fibres construit pour fournir une intégrité structurelle à la bande composite de matière de captage pour lit de fibres (37, 37', 37"),
    une couche intérieure (57, 57', 57") comprenant un tapis de fibres construit pour fournir une intégrité structurelle à la bande composite de matière de captage pour lit de fibres (37, 37', 37"), et
    une couche intermédiaire (61, 61', 61") prise en sandwich entre les couches extérieure et intérieure (59, 59', 59", 57, 57', 57"), la couche intermédiaire (61, 61', 61") n'étant pas aiguilletée, les couches intérieure et extérieure (57, 57', 57", 59, 59', 59") étant jointes l'une à l'autre au moins au niveau d'une de leurs marges de bord longitudinal des couches intérieure et extérieure (57, 57', 57", 59, 59', 59").
  2. Ensemble lit de fibres (19) selon la revendication 1, dans lequel la bande composite de matière de captage pour lit de fibres (37, 37') possède une largeur inférieure à une hauteur de la paroi de support de lit de fibres (27, 29), la bande composite de matière de captage pour lit de fibres (37, 37') étant enveloppée dans de multiples spires (39) autour du support de lit de fibres (27, 29, 34), au moins certaines des spires s'étendant le long d'un trajet en spirale.
  3. Ensemble lit de fibres (19) selon la revendication 2, dans lequel au moins certaines des spires (39) de la bande composite de matière de captage pour lit de fibres (37, 37') chevauchent des spires adjacentes des spires (39).
  4. Ensemble lit de fibres (19) selon la revendication 3, dans lequel les spires adjacentes (39) de la bande composite de matière de captage pour lit de fibres (37, 37') se chevauchent afin de former un porte-à-faux de drainage (71) à l'emplacement où les spires adjacentes (39) se chevauchent, permettant ainsi à un bord inférieur de la spire de la bande composite de matière de captage pour lit de fibres (37, 37') de drainer un liquide à partir de la spire (39).
  5. Ensemble lit de fibres (19) selon la revendication 4, comprenant en outre une couche de matériau de drainage (242) disposée entre des spires adjacentes (39) de la bande composite de matière de captage pour lit de fibres (37, 37') et faisant généralement saillie en dessous du porte-à-faux (71).
  6. Ensemble lit de fibres (19) selon la revendication 5, comprenant en outre une couche de matériau de drainage maîtresse (241) positionnée dans une relation généralement opposée avec des parties de la couche de drainage (242) faisant saillie à partir d'entre des spires adjacentes (39) de la bande composite de matière de captage pour lit de fibres (37, 37') pour recevoir un liquide et des corps solides solubles captés destinés à être drainés à partir de la couche de drainage (242) entre les spires adjacentes (39).
  7. Ensemble lit de fibres (19) selon la revendication 3, dans lequel le chevauchement de spires adjacentes (39) de la bande de matière de captage pour lit de fibres est suffisant pour empêcher un gaz de contourner le lit de fibres (35) à l'emplacement du chevauchement.
  8. Ensemble lit de fibres (19) selon la revendication 7, dans lequel les spires adjacentes se chevauchant (39) de la bande de matière de captage pour lit de fibres (37, 37') présentent un chevauchement d'entre environ deux pouces (5 cm) et environ six pouces (15 cm).
  9. Ensemble lit de fibres (19) selon la revendication 3, dans lequel la couche extérieure (59, 59') comporte des indications (69) sur celle-ci destinées à être utilisées dans l'alignement d'un bord longitudinal de la bande composite de matière de captage pour lit de fibres (37, 37') d'une spire (39) de la bande composite de matière de captage pour lit de fibres (37, 37') avec la spire précédente (39) de la bande composite de matière de captage pour lit de fibres (37, 37').
  10. Ensemble lit de fibres (19) selon la revendication 3, dans lequel la bande de matière de captage pour lit de fibres (37, 37') constitue une première bande de matière de captage pour lit de fibres (437'), le lit de fibres comprenant en outre une seconde bande de matière de captage pour lit de fibres (437") recouvrant la première bande de matière de captage pour lit de fibres (437').
  11. Ensemble lit de fibres (19) selon la revendication 1, dans lequel l'épaisseur comprimée de la bande composite de matière de captage pour lit de fibres (37, 37') est inférieure ou égale à environ 0,6 pouce (1,5 cm).
  12. Ensemble lit de fibres (19) selon la revendication 1, dans lequel la couche extérieure (59, 59') et la couche intérieure (57, 57') comprennent chacune des fibres présent un diamètre moyen d'environ 6 microns ou plus et la couche intermédiaire (61, 61') comprend des fibres présent un diamètre moyen d'environ 5 microns ou moins.
  13. Ensemble lit de fibres (19) selon la revendication 12, dans lequel les fibres de la couche extérieure (59, 59'), de la couche intérieure (57, 57') et de la couche intermédiaire (61, 61') sont faites de verre, et dans lequel les fibres des couches intérieure et extérieure (57, 57', 59, 59') sont aiguilletées.
  14. Ensemble lit de fibres (19) selon la revendication 1, dans lequel le lit de fibres (35') comprend en outre une couche de drainage (41'), la couche de drainage (41') étant prise en sandwich entre la couche intérieure (57') et la couche extérieure (59').
  15. Ensemble lit de fibres (19) selon la revendication 14, dans lequel les fibres de la couche extérieure (59'), de la couche intérieure (57') et de la couche intermédiaire (61') sont plus résistantes au mouillage par l'aérosol dans le courant gazeux que des fibres de la couche de drainage (41').
  16. Ensemble lit de fibres (19) selon la revendication 1, dans lequel les marges de bord longitudinal des couches extérieure et intérieure (59, 59', 59", 57, 57', 57") sont jointes l'une à l'autre par au moins un de : couture, agrafage, thermofusion et collage.
  17. Ensemble lit de fibres (19) selon la revendication 1, dans lequel la couche intermédiaire (61, 61', 61 ") est un matelas de fibres réalisé par fusion-soufflage.
  18. Ensemble lit de fibres (19) selon la revendication 1, dans lequel les fibres de la couche intermédiaire (61, 61', 61") sont dépourvues de liaison chimique les unes avec les autres.
  19. Ensemble lit de fibres (19) selon la revendication 1, dans lequel la paroi de support de lit de fibres (27, 29) comprend un tamis intérieur (27) et un tamis extérieur (29) agencés dans une relation généralement opposée, le lit de fibres (35) étant disposé entre les tamis intérieur et extérieur (27, 29), chaque tamis (27, 29) comprenant une maille comprenant des fils horizontaux (47, 51) et des fils verticaux (45, 49) se crois et étant mutuellement raccordés les uns aux autres, les tamis (27, 29) étant agencés de sorte que les fils horizontaux (47) du tamis intérieur (27) soient verticalement décalés des fils horizontaux (51) du tamis extérieur (29).
  20. Bande composite de matière de captage pour lit de fibres (37, 37', 37") pour former un lit de fibres (35) d'un éliminateur de brouillard (1) utilisé pour éliminer des aérosols et/ou corps solides solubles mouillés à partir d'un courant gazeux mobile, le lit de fibres (35) étant adapté pour couvrir une structure de support (27, 29, 34) du éliminateur de brouillard (1) pour bloquer l'écoulement du courant gazeux à travers la structure de support (27, 29, 34) sauf à travers le lit de fibres (35), la bande de matière de captage pour lit de fibres (37, 37', 37") comprenant :
    une couche extérieure (59, 59', 59") comprenant un tapis de fibres construit pour fournir une intégrité structurelle à la bande composite de matière de captage pour lit de fibres (37, 37', 37");
    une couche intérieure (57, 57', 57") comprenant un tapis de fibres construit pour fournir une intégrité structurelle à la bande composite de matière de captage pour lit de fibres (37, 37', 37") ; et
    une couche intermédiaire (61, 61', 61") prise en sandwich entre les couches extérieure et intérieure (59, 59', 59", 57, 57', 57"), la couche intermédiaire (61, 61', 61") n'étant pas aiguilletée, les couches intérieure et extérieure (57, 57', 57", 59, 59', 59") étant jointes l'une à l'autre le long d'au moins une marge de bord longitudinal des couches intérieure et extérieure (57, 57', 57", 59, 59', 59").
  21. Bande de matière de captage pour lit de fibres (37, 37', 37") selon la revendication 20, dans laquelle les couches extérieure et intérieure (59, 59', 59", 57, 57', 57") sont jointes l'une à l'autre le long de l'au moins une marge de bord longitudinal des couches extérieure et intérieure (59, 59', 59", 57, 57', 57") par au moins un de : couture, agrafage, thermofusion et collage.
  22. Bande de matière de captage pour lit de fibres (37, 37', 37") selon la revendication 21, dans laquelle la couche intermédiaire (61, 61', 61 ") est jointe aux couches extérieure et intérieure (59, 59', 59", 57, 57', 57") le long de ladite une marge de bord longitudinal.
  23. Bande de matière de captage pour lit de fibres (37, 37', 37") selon la revendication 21, dans laquelle les couches extérieure et intérieure (59, 59', 59", 57, 57', 57") sont jointes l'une à l'autre le long des deux marges de bord longitudinal des couches extérieure et intérieure (59, 59', 59", 57, 57', 57").
  24. Bande de matière de captage pour lit de fibres (37, 37') selon la revendication 20, dans laquelle l'épaisseur non comprimée de la bande composite de matière de captage pour lit de fibres (37, 37') est inférieure ou égale à environ 1,2 pouce (3 cm).
  25. Bande de matière de captage pour lit de fibres (37, 37') selon la revendication 20, dans laquelle les couches extérieure et intérieure (59, 59', 57, 57') comprennent chacune des fibres présentant un diamètre moyen d'environ 6 microns ou plus et la couche intermédiaire (61, 61') comprend des fibres présentant un diamètre moyen d'environ 5 microns ou moins.
  26. Bande de matière de captage pour lit de fibres (37, 37') selon la revendication 25, dans laquelle les fibres de la couche extérieure (59, 59'), de la couche intérieure (57, 57') et de la couche intermédiaire (61, 61') sont faites de verre, et dans laquelle les couches extérieure et intérieure (59, 59', 57, 57') sont aiguilletées,
  27. Bande de matière de captage pour lit de fibres (37') selon la revendication 20, comprenant en outre une couche de drainage (41') prise en sandwich entre la couche intérieure (57') et la couche extérieure (59') à l'intérieur de la bande composite de matière de captage pour lit de fibres (37').
  28. Bande de matière de captage pour lit de fibres (37') selon la revendication 27, dans laquelle les fibres de la couche extérieure (59'), de la couche intérieure (57') et de la couche intermédiaire (61') sont traitées afin de les rendre résistantes au mouillage par l'aérosol dans le courant gazeux et les fibres de la couche de drainage (41') sont dépourvues de tout traitement pour les rendre résistantes au mouillage par l'aérosol.
  29. Bande de matière de captage pour lit de fibres (37, 37') selon la revendication 20, dans laquelle la couche extérieure (59, 59') comporte des indications (69) sur celle-ci destinées à être utilisées dans l'alignement d'un bord longitudinal de la bande composite de matière de captage pour lit de fibres (37, 37') d'une spire (39) de la bande composite de matière de captage pour lit de fibres (37, 37') avec une spire précédente (39) de la bande composite de matière de captage pour lit de fibres (37, 37') lorsque la bande composite de matière de captage pour lit de fibres (37, 37') est enveloppée auto de la structure de support (27, 29, 34) du éliminateur de brouillard (1).
  30. Bande de matière de captage pour lit de fibres (37, 37') selon la revendication 20, dans laquelle la couche intermédiaire (61, 61') comprend des fibres présentant un diamètre moyen d'environ 3 microns ou moins intercalées dans des fibres présentant un diamètre moyen supérieur, les fibres intercalées présentant un diamètre moyen se trouvent dans la plage d'environ 0,01 micron à environ 3 microns.
EP06717655A 2005-01-07 2006-01-05 Bande collectrice de fibres pour un devesiculeur Active EP1855781B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP12157187A EP2510997A1 (fr) 2005-01-07 2006-01-05 Bande collectrice de fibres pour éliminateur de brouillard
PL06717655T PL1855781T3 (pl) 2005-01-07 2006-01-05 Taśma z włóknistego tworzywa gromadzącego do odemglacza

Applications Claiming Priority (2)

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US11/031,820 US7387656B2 (en) 2005-01-07 2005-01-07 Fiber collecting media strip for a mist eliminator
PCT/US2006/000482 WO2006074383A2 (fr) 2005-01-07 2006-01-05 Bande collectrice de fibres pour un devesiculeur

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EP12157187A Division EP2510997A1 (fr) 2005-01-07 2006-01-05 Bande collectrice de fibres pour éliminateur de brouillard
EP12157187.1 Division-Into 2012-02-27

Publications (2)

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EP1855781A2 EP1855781A2 (fr) 2007-11-21
EP1855781B1 true EP1855781B1 (fr) 2013-03-13

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EP12157187A Withdrawn EP2510997A1 (fr) 2005-01-07 2006-01-05 Bande collectrice de fibres pour éliminateur de brouillard

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EP (2) EP1855781B1 (fr)
JP (1) JP2008526495A (fr)
KR (1) KR20070114716A (fr)
CN (3) CN103100273B (fr)
AP (1) AP2371A (fr)
AU (1) AU2006203875B2 (fr)
ES (1) ES2411978T3 (fr)
MA (1) MA29164B1 (fr)
PL (1) PL1855781T3 (fr)
RU (1) RU2376056C2 (fr)
TN (1) TNSN07242A1 (fr)
WO (1) WO2006074383A2 (fr)
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AP2371A (en) 2012-03-02
RU2007130082A (ru) 2009-02-20
EP2510997A1 (fr) 2012-10-17
KR20070114716A (ko) 2007-12-04
CN103100273A (zh) 2013-05-15
US20080314009A1 (en) 2008-12-25
JP2008526495A (ja) 2008-07-24
PL1855781T3 (pl) 2013-08-30
AP2007004086A0 (en) 2007-08-31
MA29164B1 (fr) 2008-01-02
ZA200705188B (en) 2009-09-30
WO2006074383B1 (fr) 2007-04-26
CN101632888A (zh) 2010-01-27
TNSN07242A1 (en) 2008-11-21
WO2006074383A3 (fr) 2007-02-08
US20060150594A1 (en) 2006-07-13
ES2411978T3 (es) 2013-07-09
CN101111298A (zh) 2008-01-23
EP1855781A2 (fr) 2007-11-21
AU2006203875A1 (en) 2006-07-13
US7387656B2 (en) 2008-06-17
CN101632888B (zh) 2013-05-15
US7758665B2 (en) 2010-07-20
CN100548438C (zh) 2009-10-14
WO2006074383A2 (fr) 2006-07-13
RU2376056C2 (ru) 2009-12-20
AU2006203875B2 (en) 2011-02-24
CN103100273B (zh) 2016-01-20

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